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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page

1

January 1999

SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR CONTROLLERS

AND SERIES PUMP MOTOR CONTROL

INSTALLATION AND OPERATION MANUAL

(IC3645SR4U454Z2 IC3645SR4U454Z3, IC3645SR4U454Z4,

IC3645SR3U454Z2, IC3645SR3U454Z3, IC3645SR3U454Z4 ,

and IC3645SP4U450Z1)

Note: The information contained herein is intended to assist OEM's, Dealers and Users of
electric vehicles in the application, installation and service of GE solid-state controllers. This
manual does not purport to cover all variations in OEM vehicle types. Nor does it provide for
every possible contingency to be met involving vehicle installation, operation or maintenance.
For additional information and/or problem resolution, please refer the matter to the OEM vehicle
manufacturer through his normal field service channels. Do not contact GE directly for this
assistance.

Copyright by General Electric Company January 1999

Section 1.0

INTRODUCTION .......................................................................................................... 5

1.1

Motor Characteristics.................................................................................. 5

1.2

Solid-State Reversing.................................................................................. 6

1.3

Flexible System Application ........................................................................ 6

1.4

More Features with Fewer Components ........................................................ 6

Section 2.0

FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .............................................. 7

2.1

Performance............................................................................................... 7

2.1.1

Oscillator Card Features........................................................................ 7

2.1.1.a

Standard Operation......................................................................... 7

2.1.1.b

Proportional Operation for Dual Motor Vehicles .................................. 7

2.1.1.c

Creep Speed .................................................................................. 7

2.1.1.d

Controlled Acceleration and 1A Time ................................................ 7

2.1.2

Current Limit ........................................................................................ 8

2.1.3

Braking................................................................................................ 8

Table of Contents

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Содержание IC3645SP4U450Z1

Страница 1: ...contingency to be met involving vehicle installation operation or maintenance For additional information and or problem resolution please refer the matter to the OEM vehicle manufacturer through his normal field service channels Do not contact GE directly for this assistance Copyright by General Electric Company January 1999 Section 1 0 INTRODUCTION 5 1 1 Motor Characteristics 5 1 2 Solid State Re...

Страница 2: ...3 2 Status Codes 10 2 3 2 a Standard Codes 10 2 3 2 b Stored Codes 10 2 3 3 Hourmeter Readings 10 2 3 3 a Maintenance Alert and Speed Limit 10 2 3 4 Battery Discharge Indication BDI 10 2 3 4 a Internal Resistance Compensation 10 2 3 5 Handset 10 2 3 6 RS 232 Communication Port 11 2 3 6 a Dash Display Interaction Modes 11 2 3 7 Circuit Board Coil Driver Modules 11 2 3 8 Truck Management Module TMM ...

Страница 3: ...5 4 Connection Diagrams 56 5 4 1 TMM7A Card Connections 56 5 4 2 TMM7A Typical Brush Wear Sensor Connections 56 5 4 3 TMM Pump Control Connections 57 5 4 4 Typical Brush Wear Sensor Connections For Pump Control 57 5 5 TMM7A Outline Diagrams 57 Section 6 0 SX FAMILY GE HANDSET INSTRUCTIONS 58 6 1 General Features 58 6 2 Purpose Setup Functions 58 6 3 Setup Function Procedures 59 6 3 1 Setup Mode 59...

Страница 4: ...INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 4 January 1999 Section 9 0 MEMORY MAPS 72 9 1 Typical Memory Map for Single Motor and DM Proportioning Control 72 74 Table of Contents Continued ...

Страница 5: ...ical performance curves of Figure 1 the high torque at low speed characteristic of the series motor is evident In a shunt motor the field is connected directly across the voltage source and is therefore independent of variations in load and armature current If field strength is held constant the torque developed will vary directly with the armature current If the mechanical load on the motor incre...

Страница 6: ...hed by placing a resistor in parallel with the field winding of the motor Bypassing some of the current flowing in the field into the resistor causes the field current to be less or weakened With the field weakened the motor speed will increase giving the effect of overdrive To change the overdrive speed it is necessary to change the resistor value In a separately excited motor independent control...

Страница 7: ...wheel A potentiometer is attached to the steer wheel in order to communicate the steer angle to the controllers During vehicle manufacture software selection identifies each control for its application as a right or left control The controls are physically identical and it is only software that separates a right from a left control or differentiates a control for a dual motor application from one ...

Страница 8: ...r be maintained the braking function is canceled The fields will then reverse and the control reverts back to motoring Part of the energy produced by the motor during regen is returned to the battery and part is dumped in the motor as heat Section 2 1 3 c Pedal Position Plug Braking This feature allows control of the plugging distance based on pedal position when there has been a directional switc...

Страница 9: ...rs are on board the control card These contactors must have coils rated for the vehicle battery volts Section 2 2 System Protective Override Section 2 2 1 Static Return to Off SRO This inherent feature of the control is designed to require the driver to return the directional lever to the neutral position anytime he leaves the vehicle and returns Additionally if the seat switch or key switch is op...

Страница 10: ...f the logic card With the status code number follow the procedures outlined in DIAGNOSTIC STATUS CODES to determine the problem and a solution Note The Status Code Instruction Sheets do not purport to cover all possible causes of a display of a status code They do provide instructions for checking the most direct inputs that can cause status codes to appear Section 2 3 2 b Stored Status Codes This...

Страница 11: ...whenever a normally open switch or sensor wire provides a signal to the Module The TMM Module can be used to display a separate status code indicating over temperature of traction motors hydraulic motors or any other device or system that can activate a switch that closes The TMM Module can also be used as a Brush Wear Indicator BWI The Brush Wear Indicator is designed to detect a worn out brush a...

Страница 12: ... current limit The controlled acceleration circuit is adjustable and operates the same as the traction circuit Adjustment range is from 0 1 to 5 5 seconds The variable resistor input will override the fixed motor volt limits set by the four 4 adjustable Speed Limits It will vary motor volts above the set limits up to full motor volts and closes P1A as resistance is decreased to less than 200 ohms ...

Страница 13: ... Number Argument 02 Control Type SH Separately Excited Control Plugging SR Separately Excited Control Regen to Zero Argument 03 Operating Voltage 1 120 volts 5 36 48 volts 2 24 volts 6 24 36 volts 3 36 volts 7 72 80 volts 4 48 volts Argument 04 Package Size D 6 86 X 6 67 R 6 86 X 8 15 U 8 66 X 8 13 W 8 66 X 10 83 Argument 05 Armature Current 2 characters 22 220 Amps 33 330 Amps 40 400 Amps etc Arg...

Страница 14: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 14 January 1999 Section 3 2 Outline SR 3 Package Size ...

Страница 15: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 15 January 1999 Section 3 3 Outline SX 3 Package Size ...

Страница 16: ...P21 P13 ACC POT STEER ANGLE POT SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT STEER PUMP FIELD STEER PUMP ARM P11 P18 SP DVR PLUG RGN OUTPUT P7 P12 P6 P2 P1 P3 P4 P5 LEFT CONTROL MASTER RIGHT CONTROL SLAVE TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE PIN 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION CLOCK OUT TMM7A POWER SUPPLY 5V Y PLUG CONNECTIONS DATA OUT ENABLE OUT NEGATIVE COMMON 5 V CONT STORE ...

Страница 17: ... FIELD ARMATURE FU1 FU5 KEY SWITCH P1 P2 P10 P6 P5 P16 94 INPUT 94 INPUT 90 INPUT P13 P11 91 INPUT BRUSHWEAR OUTPUT P14 P14 OVER TEMP OUTPUT P20 P15 92 INPUT ELEMENTARY DRAWING FOR PUMP MOTOR CONTROLLER P12 P9 95 INPUT P8 95 INPUT LINE FU6 P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI ...

Страница 18: ...OT USED TMM1 BRUSHWEAR INDICATER OUTPUT 14 N O BRAKE SW TMM1 OVER TEMPERATURE OUTPUT 15 IMOTOR OUT STATUS CODE 92 INPUT 16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CONTACTOR DRIVER 18 1A OR STEER PUMP CTR DRIVER AND SUPPRESSION 1A CONTACTOR DRIVER 19 STEER ANGLE POT 5 VOLTS SUPPLY SPEED LIMIT 2 INPUT 20 NOT USED SPEED LIMIT 3 INPUT 21 PMT ENABLE...

Страница 19: ...rcent discharged with periodic equalizing charges Visual inspection of GE contactors contained in the traction and pump systems is recommended to occur during every 160 hours of vehicle operation Inspection is recommended to verify that the contactors are not binding and that the tips are intact and free of contaminants GE does not recommend that any type of welding be performed on the vehicle aft...

Страница 20: ...e used for all levels of cabling All cables and wires of like signal levels and power levels must be grouped together In general different levels must run in separate wire bundles as defined in the different classes identified above Intermixing cannot be allowed unless noted by exception Interconnecting wire runs should carry a level designation If wires are the same level and same type signal gro...

Страница 21: ...ed and lubricated prior to shipment from the factory However in applications where severe vibration or high temperature cycling and excessive humidity such as freezers are present it is recommended that the plug terminals be cleaned and lubricated every year per this instructions In normal applications plug maintenance should be performed every two years unless intermittent problems arise with the...

Страница 22: ...y vary Refer to the elementary and wiring diagrams for your specific control The wire numbers shown on the elementary diagram will have identical numbers on the corresponding wiring diagrams for a specific vehicle but these numbers may be different from the numbers referenced in this publication WARNING Before trouble shooting jack up the drive wheels disconnect the battery and discharge the capac...

Страница 23: ...uit or loose connection going from the Y plug and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG FU3 KEY SWITCH P1 P2 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 01 No seat switch or deadman switch input no voltage to P6 This status code will be displayed when P6 is less than 50 battery volts MEMORY RECALL NO CORRECTIVE A...

Страница 24: ...ive control Replace the controller unit KEY SWITCH P1 P2 P3 BRAKE SWITCH P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 03 Reverse directional switch is closed on initial power up This status code will be displayed when P5 is greater than 60 of battery voltage at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIO...

Страница 25: ...r switch potentiometer for proper operation and ohmic value KEY SWITCH BRAKE SWITCH REVERSE SW FORWARD SW SEAT SWITCH L START SW P8 P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 Accelerator depressed with no direction selected This status code will be displayed when P4 and P5 are less than 60 of battery volts and P7 is less than 2 5 vol...

Страница 26: ...or input circuit Disconnect wire from P7 and measure voltage at wire to negative Should be zero volts for potentiometer type and less than 3 7 volts for solid state type accelerator input P9 P7 P8 ACC POT P7 P8 ACC POT TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 08 Accelerator input voltage too low on power up after initial key switch closure This status code will be disp...

Страница 27: ... and check wire for short circuit to positive side of directional switch Defective Control Disconnect wires and measure voltage at P4 and P5 Voltage should be less than 60 of battery volts KEY SWITCH P1 P2 P3 BRAKE SWITCH P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 10 Steer angle potentiometer voltage is too high T...

Страница 28: ...ect wire from P3 Check for short circuit from this wire to battery positive Resistance should be greater than 4 7K ohms Defective control Disconnect wire from P3 Measure voltage from P3 to negative Voltage should be zero if not replace control KEY SWITCH P1 P2 P3 BRAKE SWITCH P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICA...

Страница 29: ... settings Check minimum battery volts at P1 and NEG NEG FU3 P1 NOMINAL BATTERY VOLTAGE MINIMUM LIMIT VOLTS AT 1 95 VDC PER CELL 24 80 48 72 36 23 4 78 0 46 8 70 2 35 1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 16 Battery voltage is too high or control card is mis adjusted This status code will be displayed when the battery volts are greater than 2 4 volts per cell at in...

Страница 30: ... set card type value as instructed by OEM service manual NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is high on start up in the reverse direction This status code will be displayed when the current draw in the motor field is too high at start up in the reverse direction MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOO...

Страница 31: ...EY SWITCH P8 P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW BRAKE SW ACC POT LINE L REVERSE SW SEAT SW P5 FU1 PLUG PL2 P9 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 27 Power supply is less than 10 Volts DC This status code will be displayed when the power supply is less than 10 volts MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Con...

Страница 32: ...SE OF STATUS INDICATION 29 Motor armature current is too high during the run mode Dual Motor Proportioning Controls Only This status code will be displayed when the motor current in control A is greater than 125A while the motor current in control B is less than 26A for a 16 second interval MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM...

Страница 33: ...ary control P7 P8 P1 P17 P2 P6 P9 P3 P12 P8 P4 P5 P23 P22 P10 P21 P13 ACC POT STEER ANGLE POT SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 BRAKE SW P11 P18 1A OR SP DVR PLUG RGN OUTPUT P7 P12 P6 P2 P1 P3 P4 P5 LEFT CONTROL MASTER RIGHT CONTROL SLAVE AUXILIARY P10 P13 SPEED LIMIT SWITCH P16 P15 P15 P16 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Open thermal protect...

Страница 34: ...ion Controller SYMPTOM Control will not operate POSSIBLE CAUSE Defective control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 43 Motor armature offset voltage is too low This status code will be displayed when the voltage at the current sensor input is less than 2 4 volts with no current flowing in the motor circuit M...

Страница 35: ...UG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 45 Armature transistor did not turn on properly This status code will be displayed when during control operation the armature transistor fails to turn on properly This will result in a PMT condition...

Страница 36: ...R CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE L P1 P17 P2 P6 P3 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW P23 P22 P10 P13 SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 P15 I MOTOR OUTPUT BRAKESW STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAK...

Страница 37: ...2 FIELD ARMATURE FU4 A1 A2 S1 S2 SP FU1 POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE L P1 P17 P2 P6 P3 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW P23 P22 P10 P13 SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 P15 I MOTOR OUTPUT BRAKESW STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE...

Страница 38: ...trol is reset by recycling the key switch MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Defective control Replace controller unit Line contactor tips welded open Replace line contactor Verify that there are no motor shorts Verify that there are no cable shorts between B and F1 B and F2 A2 and F2 ...

Страница 39: ... SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 P15 I MOTOR OUTPUT BRAKESW STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 68 The PMT enable signal from the auxiliary slave control to the m...

Страница 40: ...T BDI INTERRUPT P14 P15 I MOTOR OUTPUT BRAKESW STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 77 Motor current is detected during regenerative braking This status code will be displayed when...

Страница 41: ... PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 81 Battery voltage is less than 14 volts This status code will be displayed when the battery voltage measured at P1 is less than 14 volts MEMORY REC...

Страница 42: ...MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW Section 4 5 TMM Codes TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 90 USER DEFINED STATUS CODE See instructions for Truck Management Module for details This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at zer...

Страница 43: ... card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 P17 SC91 WHEN TMM7A CARD IS USED NEG USER SW WHEN SR Series PUMP CONTROL IS USED NEG USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 92 USER DEFINED STATUS CODE See instructions for Truck Management Module for details This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card i...

Страница 44: ... card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 POS SC93 WHEN TMM7A CARD IS USED POS USER SW P3 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 93 USER DEFINED STATUS CODE See instructions for Truck Management Module for details This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is...

Страница 45: ... card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 SC94 WHEN TMM7A CARD IS USED POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED POS USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 94 USER DEFINED STATUS CODE See instructions for Truck Management Module for details This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is...

Страница 46: ... card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 SC95 WHEN TMM7A CARD IS USED POS P8 USER SW WHEN SR Series PUMP CONTROL IS USED POS USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 95 USER DEFINED STATUS CODE See instructions for Truck Management Module for details This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is...

Страница 47: ...D SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 103 Key switch is open for more than 8 seconds while the SL3 switch is closed This status code will be displayed when SL3 is closed with the key switch off MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE...

Страница 48: ... BRUSHWEAR OUTPUT P14 P14 OVER TEMP OUTPUT P20 P15 92 INPUT P12 P9 95 INPUT P8 95 INPUT FU6 P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 117 Card Type selection is invalid This status code will ...

Страница 49: ...ould be between 10 and 14 ohms POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 LINE FU5 KEY SWITCH P1 P2 FU6 P 1A P17 P18 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 124 T2 voltage is low Less than 88 of battery voltage This status code is displayed when T2 voltage is less than 88 of battery volts and the Pump driver is energized MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE...

Страница 50: ...D LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 128 Armature current is greater than 300A for longer than 70 seconds This status code is displayed when armature current is maintained at a level above 300A for 70 seconds MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHO...

Страница 51: ...t back Allow control to cool status code should disappear If control cools to ambient temperature and the fault remains when the control is restarted replace the control NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 142 Pump Controller motor current sensor input is missing This status code is displayed when the voltage at the current sensor is gr...

Страница 52: ...OM No power to pump motor in control range POSSIBLE CAUSE Control is defective Replace controller unit NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 144 Power Transistor Q1 did not turn off properly This status code is displayed when during pump control operation the Q1 transistor fails to turn off This will result in a PMT condition MEMORY RECAL...

Страница 53: ...ARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 146 Look Ahead test for T2 volts less than 12 of battery volts This status code will be displayed when the voltage at A2 is less than 12 of battery volts MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE...

Страница 54: ... 94 INPUT 90 INPUT P13 P11 91 INPUT BRUSHWEAR OUTPUT P14 P14 OVER TEMP OUTPUT P20 P15 92 INPUT P12 P9 95 INPUT P8 95 INPUT FU6 P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 157 Controller motor c...

Страница 55: ...P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 181 Battery voltage is less than 14 volts This status code will be displayed when the battery voltage measured at P1 is less than 14 volts MEMORY RECALL ...

Страница 56: ...he status code displayed for each input when that point is closed to battery negative or positive as indicated TMM7A Pump Card Control Status Terminal Terminal Code Connect To TB1 P16 90 Neg TB3 P11 91 Neg TB4 P15 92 Neg TB5 P3 93 Pos TB6 P4 93 Pos TB8 P5 94 Pos TB10 P6 94 Pos TB11 P8 95 Pos TB12 P9 95 Pos Status codes 90 and 93 can also be programmed with the Handset to reduce the speed of the tr...

Страница 57: ...PA 2 PA 4 PA 5 PZ 10 PZ 11 PY 10 PA 3 1 A1 1 A1 2 A2 1 A3 1 A2 2 A3 2 TO PY10 TRACTION Section 5 4 4 Typical Brush Wear Sensor Connections For Pump Control ARM 1 BRUSH WEAR SENSOR CONNECTIONS FOR PUMP CONTROL TYPICAL PA 1 PA 2 PA 4 PA 5 PZ 10 PZ 11 2 1 TRACTION PUMP PWR STEER ARM 2 2 1 ARM 3 2 1 Section 5 5 TMM7A Outline Drawings 1 3 4 5 6 7 2 8 10 9 11 12 14 13 15 5 8 147 20 6 15 156 20 8 20 3 3 ...

Страница 58: ...y Voltage 36 48 volts is auto ranging Selection of Card Operation Type At the transistor control traction card unplug the Y plug if the dash display is in use and plug in the Handset to the plug location Y on the control card After installing the Handset tool plug the battery in and turn the key switch on The chart at the right details the start up display sequence that will occur START UP DISPLAY...

Страница 59: ...r a blank display if BDI is not used and there are no fault codes The vehicle can now be operated with the Handset connected or the Handset can be disconnected before operation NOTE You can return to the segment check mode at any time by holding down the ESC key until 8888 appears in the display Section 6 3 2 Status Code Scrolling The SX family of controllers furnishes a function register that con...

Страница 60: ...f vehicle development This setting must not be changed by field personnel without the permission of the OEM FUNCTION 3 ARMATURE CONTROLLED ACCELERATION AND 1A TIME Push 3 This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100 applied battery voltage to the motor on hard acceleration Range 0 1 to 25 5 seconds Set 1 to 255 Resolution 0 1 seconds per...

Страница 61: ...ment of the maximum field current to be used during the regen braking mode Resolution Example Min Max Set Per unit value If set at 71 0 40 51 to 255 0 185 amps 3 7 amps Important Note The function is used to optimize motor and control performance and this setting will be determined by GE and OEM engineers at the time of vehicle development This setting must not be changed by field personnel withou...

Страница 62: ...ect on plugging distance Note Vehicles equipped with regenerative braking will vary the regen current with pedal position However minimum regen current is fixed at 50 amps The pedal position will vary regen current between 50 amps and the maximum value of regen current set by Function 9 FUNCTION 17 CARD TYPE SELECTION Push CONT 2 This function allows for the selection of the card type used for you...

Страница 63: ...etting 0 to 255 Resolution 815 per set unit Example Setting of 20 20 815 52 68 3 FUNCTION 24 FIELD WEAKENING START Push CONT 9 This function allows for setting the armature current at which minimum field current will be achieved Range 0 to 414 amps Setting 0 to 255 Resolution 1 625 per set unit Example Setting of 20 32 5 amps FUNCTION 25 MONITOR Push CONT 10 This function allows the monitoring of ...

Страница 64: ...RE CONTROLLED ACCELERATION AND 1A TIME Push CONT 5 Same as Function 48 This C A AND 1A TIME takes effect when the Mode 2 settings are called for by the Interactive Dash Display FUNCTION 53 MODE 2 REGEN CURRENT LIMIT Push CONT 6 Same as Function 49 This FIELD WEAKENING START takes effect when the Mode 2 settings are called for by the Interactive Dash Display FUNCTION 54 MODE 2 BRAKE PEDAL REGEN Pus...

Страница 65: ...by the Interactive Dash Display FUNCTION 60 MODE 4 ARMATURE CONTROLLED ACCELERATION AND 1A TIME Push CONT 13 Same as Function 48 This C A AND 1A TIME takes effect when the Mode 4 settings are called for by the Interactive Dash Display FUNCTION 61 MODE 4 REGEN CURRENT LIMIT Push CONT 14 Same as Function 49 This FIELD WEAKENING START takes effect when the Mode 4 settings are called for by the Intera...

Страница 66: ...unction 4 The function along with the maximum field current Function 8 sets the maximum torque of the motor The field weakening start setting is adjusted by Function 24 This function sets the armature current at which minimum field current will achieved The ratio setting is adjusted by Function 26 This function sets the ratio between armature and field current when transitioning from minimum field...

Страница 67: ...any of four pre set interactive modes consisting of 4 Controlled Acceleration levels 4 Field Weakening Pick Up levels and 4 Speed Limit levels These interactive modes are pre set using the Handset Functions 48 63 or a personal computer Functions 97 112 This feature allows the operator to select the best vehicle performance for changing factory task conditions The Custom Dash Display incorporates a...

Страница 68: ... Display no BDI used Diagnostics Override With Fault Run Mode BDI Display or Blank Display no BDI used Diagnostics Override With Fault Key Switch Off Display TractionHourmeter For Four Seconds Display PumpHourmeter For Four Seconds Section 7 5 Outline Drawings g GE Electric Vehicle Motors Controls PY3 PY4 PY2 PY1 PY5 1 2 3 4 5 5 4 3 2 1 PY3 PY4 PY2 PY1 PUMP TRACTION BACK VIEW OF DISPLAY Wiring con...

Страница 69: ...two vehicle speed limit enable points during the transition from 16o to 66o Speed limit 1 can be enabled at 41o and speed limit 2 can be enabled at 60o Between 66o and 71o the inside wheel will be in a free wheel mode As the steer reaches the 71o point the inside wheel can now be programmed to reverse and accelerate proportionally in the opposite direction Above 86o is over travel for the turn ang...

Страница 70: ...5 o 1 19V SL2 1 50V SL1 2 80V SL1 3 11V SL2 LEFT TURN RIGHT TURN 0 00V 2 15V Over Travel Reverse Direction and Re Accelerate Proportionally Reduces The Speed of the Left Motor As Steer Angle Increases No Speed Change No Speed Change Proportionally Reduces The Speed of the Right Motor As Steer Angle Increases Reverse Direction and Re Accelerate Over Travel 4 30V 41 o 60 o 41 o 60 o 270 DEGREE POTEN...

Страница 71: ... 1 83 20 93 2 47 20 126 Proportional Reduce 1 10 66 56 3 20 66 163 Creep Speed 1 82 21 93 2 48 21 127 Proportional Reduce 1 08 67 55 3 22 67 164 Zero Speed 1 80 22 92 2 50 22 128 Proportional Reduce 1 07 68 54 3 23 68 165 Zero Speed 1 78 23 91 2 52 23 128 Proportional Reduce 1 05 69 54 3 25 69 166 Zero Speed 1 77 24 90 2 53 24 129 Proportional Reduce 1 04 70 53 3 26 70 167 Zero Speed 1 75 25 89 2 ...

Страница 72: ...M Tens Units HS or PC None 19 20 20 HM Thou Hun HS or PC None 20 21 21 Auto Regen HS or PC None 21 22 22 Mode Reference HS or PC For DD on power up 22 23 23 Field PWM Gain HS or PC None 23 24 24 FW Start HS or PC None 24 25 25 Monitor HS or PC GE Temporary Storage 25 26 26 Ratio HS or PC GE Temporary Storage 26 27 27 HM Minutes HS or PC GE Temporary Storage 27 28 28 Fault Count Pointer HS or PC No...

Страница 73: ...PC Only Reset to Zero Only 66 67 Hours Tens Ones 9 PC Only Reset to Zero Only 67 68 Hours Thou Hun 9 PC Only Reset to Zero Only 68 69 36 Stored Status Code 10 PC Only Reset to Zero Only 69 70 BDI 10 PC Only Reset to Zero Only 70 71 Hours Tens Ones 10 PC Only Reset to Zero Only 71 72 Hours Thou Hun 10 PC Only Reset to Zero Only 72 73 38 Stored Status Code 11 PC Only Reset to Zero Only 73 74 BDI 11 ...

Страница 74: ... PC None 106 107 58 Dash Display Min Fld 3 HS or PC None 107 108 59 Dash Display If Im Ratio 3 SL 3 HS or PC None 108 109 60 Dash Display CA 4 HS or PC None 109 110 61 Dash Display FWS 4 Ratio2 4 HS or PC None 110 111 62 Dash Display Min Fld 4 HS or PC None 111 112 63 Dash Display If Im Ratio 4 SL 4 HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Only 113 114 Secure HM Thou Hun PC Only ...

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